WO2013115401A1 - 超伝導加速空洞の純ニオブ製エンドグループ部品の製造方法 - Google Patents
超伝導加速空洞の純ニオブ製エンドグループ部品の製造方法 Download PDFInfo
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10N60/00—Superconducting devices
- H10N60/01—Manufacture or treatment
- H10N60/0156—Manufacture or treatment of devices comprising Nb or an alloy of Nb with one or more of the elements of group 4, e.g. Ti, Zr, Hf
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/201—Work-pieces; preparation of the work-pieces, e.g. lubricating, coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/208—Deep-drawing by heating the blank or deep-drawing associated with heat treatment
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H7/00—Details of devices of the types covered by groups H05H9/00, H05H11/00, H05H13/00
- H05H7/14—Vacuum chambers
- H05H7/18—Cavities; Resonators
- H05H7/20—Cavities; Resonators with superconductive walls
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
Definitions
- the present invention relates to a method of manufacturing a pure niobium end group part of a superconducting acceleration cavity used for acceleration of (charged) particles such as a synchrotron and a linac type.
- a superconducting accelerating cavity uses a high-frequency electric field to accelerate (charged) particles with high efficiency to near the speed of light, and to resonate a metal cavity at a high frequency of a specific frequency in order to cause a collision phenomenon in the particles. It is mainly used for charged particle accelerators such as synchrotron and linac type.
- high-purity niobium is selected for the following reasons, and its material manufacturing technology and component processing technology are being developed.
- High-purity niobium belongs to a transition metal, has a body-centered cubic lattice in a wide temperature range from the melting point to extremely low temperature, and is a stable material that does not cause phase transformation.
- High-purity niobium is a very soft material near room temperature, and its strength is insufficient. Therefore, it is difficult to work, and because it is a body-centered cubic crystal lattice, it is severely hardened at low temperatures and causes brittle fracture. Although it has easy characteristics, it cannot be said that processing is impossible.
- High-purity niobium is easy to handle at room temperature because it has an oxide film formed in air and has corrosion resistance and acid resistance.
- the most important characteristic is the superconducting characteristic, that is, it is highly possible that the acceleration voltage per unit length can be taken high in the acceleration cavity.
- the superconducting performance is affected by the purity, metal structure (crystal grain size and crystal texture) and surface properties of niobium.
- a structure after processing and annealing is basically preferable to a cast structure.
- the former has a metal structure with a large aspect ratio and a small grain boundary tilt angle, so it is difficult to say that the metallographically stable state exists, and the material properties and workability are difficult.
- the latter case since it has a recrystallized structure matrix composed of large-angle boundaries, it can be said to be stable in terms of metallurgy and advantageous for material properties and workability. It is also important that the structure after processing / annealing changes depending on the manufacturing conditions of the material, and conversely, it can be controlled to some extent.
- the surface texture is important because the electric field generated in the superconducting acceleration cavity is due to the extreme skin current. Therefore, the surface of the niobium processed product is subjected to chemical polishing, electrolytic polishing, or a combination thereof.
- the superconducting accelerating cavities are composed of nine cells in the center part called “nine cavities” and end group parts HOM cup, Beam pipe, Port pipe, HOM antenna, etc. It is configured.
- the HOM cup is integrated with the HOM antenna and is referred to as a HOM coupler.
- the purpose of these parts is to increase the acceleration voltage per unit length and cause particle collisions at as high an energy as possible.
- the HOM is a harmonic mode, which is also a resonance suppression mode that interferes with particle beam acceleration.
- One that can be well coupled with the resonance suppression mode is a HOM Coupler (harmonic coupler).
- Patent Document 1 discloses a method of manufacturing a sliced Nb plate material by pressing it into a half cup and joining it by electron beam welding EBW.
- the press work is a shallow drawing method at room temperature, and is not a technique applicable to the manufacture of end group parts.
- a method of manufacturing a rod material only by machining (hereinafter, also referred to as “all-machine cutting method”).
- a method of manufacturing a combination of backward extrusion of rod material, mechanical cutting, and heat treatment (hereinafter also referred to as “extrusion-mechanical cutting-heat treatment method”).
- a method of manufacturing a sheet material by performing a plurality of press processes and a plurality of heat treatments between the press processes (hereinafter also referred to as “multiple press process-heat treatment method”).
- the manufacturing method (3) uses a plate material, there is a problem in that the press process and the heat treatment need to be performed a plurality of times, resulting in a decrease in productivity and an increase in manufacturing cost.
- the inventor once paid attention to the temperature dependence of work-induced martensitic transformation in metal materials such as austenite ( ⁇ ) stainless steel near room temperature, specifically, the temperature dependence of strength and elongation characteristics in the working process.
- the company has developed a “warm processing method” that improves the drawability of materials. To put it simply, in the drawing process, the flange part is heated to reduce work hardening due to transformation, reduce flange deformation resistance, and at the same time cool the vicinity of the punch shoulder at the fracture risk part to transform. This is based on the technical idea of improving the drawability by accelerating work hardening by increasing the punch shoulder fracture resistance and further optimizing the balance between the two (FIG. 3, Patent Document 2). To 7 and Non-Patent Documents 1 to 6).
- Kiyohiko Nohara, Hiroshi Ono “Processing-induced transformation in stainless steel” plasticity and processing, vol. 18 (1977) No. 18; 202, p. 938 Kiyohiko Nohara, Hiroshi Ono: “Warm pressing of stainless steel sheet”, Kawasaki Steel Technical Report, vol. 17 (1985) No. 17; 3, p. 315 K. Nohara, Y .; Watanabe, and K.K. Yamahata: “Warm Press Forming of Stainless Steel Sheets”, Proc. 1st. Int. Conf. on New Manufacturing Tech. (1990) Kiyohiko Nohara: “Stainless Steel and Pressing”, Press Technology, 41 (2003), No. 1, p.
- pure niobium does not cause the processing-induced martensitic transformation like the above-mentioned austenitic stainless steel, so that the above technique cannot be applied to the present invention as it is.
- Niobium is a high-priced material that is typical of rare metals, so it can maintain the superconducting properties, reduce the amount of materials used, and reduce costs. Since it has a relationship that is difficult to separate from the method, it is necessary to establish a manufacturing method in consideration of material characteristics.
- the present invention has been made in view of the above-mentioned problems of the prior art, and its purpose is to draw a deformation mode among pure niobium end group parts of a superconducting acceleration cavity used for acceleration of (charged) particles. It is to propose a new manufacturing method considering material characteristics, which is suitable for manufacturing a component mainly composed of the above.
- the present invention developed to solve the above problems is a method of manufacturing an end group component of a superconducting acceleration cavity used for acceleration of (charged) particles, and is mainly a flat bottom cylindrical drawing from a pure niobium plate material. (1st invention).
- the end group component manufacturing method of the present invention is characterized in that, in the press working, slide speed and / or motion control and mold temperature and / or distribution / gradient control are performed simultaneously ( Second invention).
- the end group component manufacturing method of the present invention is characterized in that, in the press work, the wrinkle presser load is dynamically controlled according to the change in the flange area, plate thickness and material of the pure niobium plate material. (Third invention).
- the end group part manufacturing method of the present invention uses a water-soluble solid film type lubricant having a temperature change of kinematic viscosity within ⁇ 10% within a range of ⁇ 50 to + 300 ° C. as the lubricant for press working.
- Characteristic (5th invention) is a water-soluble solid film type lubricant having a temperature change of kinematic viscosity within ⁇ 10% within a range of ⁇ 50 to + 300 ° C.
- the end group part manufacturing method of the present invention is characterized in that after the press working, a re-striking process is performed (sixth invention).
- the end group component manufacturing method according to the present invention is characterized in that after the press processing or re-striking processing, any one or more of trimming, bottom protrusion, and burring is performed (seventh invention). ).
- the end group component manufacturing method includes a servo mechanism capable of controlling the speed and / or motion of the slide and a dynamic wrinkle presser control device capable of dynamically controlling a wrinkle presser load.
- a temperature control device and a mold capable of controlling the temperature and / or distribution / gradient of the workpiece (8th invention).
- the end group part of the superconducting acceleration cavity can be manufactured only by pressing without using mechanical cutting or heat treatment.
- the amount of expensive pure niobium material can be reduced, and the material cost can be greatly reduced.
- the number of processing steps can be reduced, the manufacturing process can be simplified, and the manufacturing time can be shortened, so that mass production is possible and a significant reduction in manufacturing cost can be expected.
- the first of the problems to be solved in the present invention is a conventional method of machine cutting from a rod material (as a method of manufacturing a draw-forming main part forming the core of a superconducting acceleration cavity end group ( All-machine cutting method), processing method combining rod material back extrusion, machine cutting and heat treatment (extrusion-machine cutting-heat treatment method), or multiple pressing and multiple heat treatments on plate material It is to propose a new processing method that replaces the combined processing method (multiple press processing-heat treatment method).
- the first invention of the present invention developed to solve the above-mentioned problems is a method of manufacturing cylindrical end group parts from a pure niobium plate material mainly by press working which is a flat bottom cylindrical drawing.
- control of the speed and / or motion of the slide and control of the temperature and / or distribution / gradient of the mold. are performed simultaneously (second invention).
- speed / motion control the control of the speed and / or motion of the slide
- temperature and / or distribution / gradient control of the mold is also referred to as “temperature / distribution / gradient control”.
- second invention will be described below.
- one of the methods for processing materials that are difficult to deep-draw is to reduce the work hardening due to work-induced martensite transformation by heating the flange part in drawing and reducing the flange.
- the processing-induced martensitic transformation does not occur, so the above technique cannot be applied to the present invention as it is.
- n a work hardening index, which is an index of the following ⁇ - ⁇ power relational expression.
- A, K and m are constants, Q is activation energy, and k is Boltzmann constant.
- the inventors have examined the deformation deformation behavior of pure niobium and have confirmed that the equations (4), (5), and (6) are actually valid.
- pure niobium may differ from austenitic stainless steel because of its deformation mechanism, so only a slight effect may be obtained, but the warm working method is a means of improving workability compared to drawing at room temperature.
- the application of was examined. Then, the plate material of both materials, when performing flat bottom cylindrical drawing by press working, the flange portion temperature T d: 100 ° C., punch shoulder part temperature T p: a 5 ° C. to warm working method experiment applying the results
- FIG. 4 is an easy-to-understand and qualitative illustration.
- the drawing ratio [DR] ⁇ D 0 / D p is taken on the horizontal axis, and the flange portion load F d and the punch shoulder load F p are taken on the vertical axis. shows the temperature T d and punch shoulder temperature T p as a parameter.
- FIG. 4 shows that, as a qualitative tendency, warm working has an effect similar to transformation-induced plasticity of austenitic stainless steel even in pure niobium material.
- the conventional warm working method alone is not sufficient to achieve the object of the present invention in which end group parts are manufactured mainly by press working using a flat bottom cylindrical drawing.
- ⁇ cr (2 / ⁇ 3) 1 + n ⁇ [ ⁇ (1 + R) / 2 ⁇ / ⁇ 1 + 2R / 3 ⁇ ] 1 + n ⁇ ⁇ u (t 0 / t) (7) ( ⁇ u is the maximum tensile true stress, and t 0 and t are thicknesses before and after processing, respectively)
- the inventors use the warm working method as a starting point, but are inferior to the workability of the pure niobium material, which is soft, low strength, low work hardenability, low r value and r value in-plane.
- we conducted intensive research aimed at greatly improving workability.
- the qualitative diagram of FIG. 5 facilitates understanding. That is, when the blank is positioned, the blank is at room temperature, but the punch and the die come into contact with the blank due to the low-speed movement of the slide. temperature / distribution-gradient becomes a proper state for drawing process as shown by the thermal conduction between the stopping time t f.
- the effect of increasing the processing speed which is the second point of view, is that after making the temperature / distribution / gradient state appropriate, the processing is immediately completed in a high-speed processing state, and drawing is performed. Is to make it possible. The reason is that the stress in the vicinity of the punch shoulder increases, the dynamic friction coefficient of the flange decreases, and the undesired increase in stress in the flange decreases by dynamic control of the wrinkle presser load described later. This is due to the overall effect.
- the press processing method of the present invention in which the press workability (drawing formability) is greatly improved by combining the speed / motion control and the temperature / distribution / gradient control, the conventional room temperature processing method, warm processing method, etc.
- fusion press working method in which the press workability (drawing formability) is greatly improved by combining the speed / motion control and the temperature / distribution / gradient control, the conventional room temperature processing method, warm processing method, etc.
- the wrinkle presser load is usually set to a range where the material does not break in order to prevent wrinkling in press processing, and is usually held at a constant load until the end of processing (drawing out).
- a “variable wrinkle presser method” that dynamically changes the wrinkle presser force during the machining process while taking into account changes in the flange area as the drawing progresses, changes in the material plate thickness, and changes in the forming load. Proposed.
- This method alleviates the factors that hinder the squeezability, both the microscopic azimuth variation due to the r value of the material and its anisotropy, and the macroscopic increase in the plate thickness due to the dynamic shrinkage flange deformation. Since there is an effect, an improvement in squeezing property is expected.
- the above-described second invention of the present invention intends to improve the workability by integrating the conscious processing speed and the processing temperature distribution, and particularly by increasing the plane strain critical fracture stress ⁇ cr by increasing the speed during the processing process.
- the third invention of the present invention is not only the material hardening effect due to the increase in the processing speed, but also the change in the deformation resistance of the flange (by increasing the processing speed) In addition to changes in the lubrication state, it depends on flange area change, material thickness change, material hardening, etc.).
- the third invention of the present invention relates to the wrinkle holding load for forming a workpiece having a certain appropriate temperature / distribution / gradient, and includes three points of flange area, material plate thickness, and material hardening during the machining process ( Specifically, the temperature control is applied to control the deformation resistance of the flange from 4 points), which is newly referred to as “dynamic wrinkle presser load control”.
- the flange deformation resistance stress ⁇ d is reduced at the same time as the machining speed is increased.
- the conditions are the temperature / distribution / gradient appropriate for the workpiece.
- N times in the increase in the processing speed is a speed relative to a general speed (about 5 mm / sec) of conventional hydraulic press processing (which is slowed down by hydraulic control and copes with difficult-to-process materials to some extent). Is defined as the magnification of. This is aimed at improving the drawability by increasing the speed as well as controlling the temperature and reducing the productivity and cost.
- the anisotropy in the drawing is mainly due to the in-plane anisotropy of the material.
- the quantitative value representing the in-plane anisotropy of the material includes the above-described average value R of the r-value and the in-plane anisotropy magnitude
- niobium is the same body-centered cubic lattice (BCC) as ordinary steel such as SPC.
- BCC body-centered cubic lattice
- niobium is characterized by a large plastic strain ratio r value that is highly involved in drawability and a small average value R, but a large in-plane anisotropy
- ear the unevenness of the cylindrical edge
- pure niobium is a material (difficult to process) that is greatly inferior to a general plain steel sheet and has a high degree of processing difficulty in terms of drawability and in-plane anisotropy.
- This is considered to be related to the crystal texture due to the production conditions of the pure niobium material, but in the present invention, it is not related to the improvement of the physical properties of the material itself, that is, based on the physical properties of the current material, The focus is on improving formability and anisotropy by developing new press working methods.
- the “profile blank (cylindrical cylinder) proposed in the fourth invention of the present invention was developed.
- a non-round circle blank In the case of an aperture, a non-round circle blank.
- a cylindrical diaphragm blank (element plate) having a perfect circle shape is used. This is because ear problems do not occur if the material is isotropic.
- the plastic strain ratio r value of an actual pure niobium material has a strong direction ( ⁇ ) dependence from the rolling direction and a large in-plane anisotropy compared to a normal steel plate.
- the change in the plate thickness is small in the direction where the r value is large and large in the direction where it is small. Therefore, in the case of a cylindrical diaphragm, the flange deformation shrinks in the circumferential direction and the plate thickness direction, and the flange deformation occurs in the radial direction. Therefore, the plate thickness increases in the direction where the r value is large, and the material escapes in the radial direction. On the contrary, since the increase in the plate thickness is small in the direction in which the r value is small, the amount of the material that escapes in the radial direction is small, resulting in a concave ear.
- the above formula (9) indicates that the blank diameter D ⁇ from the rolling direction to the angle ⁇ direction is r in which the angle ⁇ from the reference rolling direction is 45 °. This is based on the idea that it is indicated by the power of the ratio of the value (r 45 ) and the r value (r ⁇ ) in an arbitrary ⁇ direction.
- the constant J is a constant determined by the anisotropy of the workpiece, and varies depending on the type of workpiece, manufacturing history, etc. In the case of a pure niobium plate material, it is generally 1/10 to 1 / It is in the range of 13. As will be described later, in the pure niobium plate material used in the examples of the present invention, the constant J at which the difference ⁇ E ⁇ 0 between the convex ear height and the concave ear height is (1 / 11.5).
- Step 1 For each material or material lot, r ⁇ (r value in the direction in which the rolling direction is 0 ° and then angle ⁇ ) is measured, for example, every 15 ° (the r value measurement method is JIS The method described in Z2254 can be used.)
- Step 2 After verifying the reliability of the r value (reproducibility confirmation, optimizing the ⁇ interval, etc.) and confirming the data by applying the least squares method, the cubic B-spline interpolation method Define the r ⁇ relationship.
- FIG. 6 An example of the deformed blank thus obtained is shown in FIG. 6 together with a conventional perfect circle blank.
- the “four ears” in the perfect circle blank are divided and isotropic, and the formability is also improved by making the flange deformation resistance stress ⁇ d uniform in the circumferential direction.
- the tensile residual stress and notch effect it is also effective in avoiding delayed fracture that tends to occur at the edge of deep-drawn products.
- FIG. 7 shows the influence of the blank shape and dimensions on the molding height of the concave ear in flat-bottom cylindrical drawing, that is, the molding height that can be used effectively (usable height).
- the conventional room temperature processing method are shown together with the HOM cup of the end group part of the superconducting acceleration cavity and the target molding height region necessary for obtaining the beam pipe. Both of the above two processing methods are based on single-step pressing.
- the lubricant (No. 1). 5 invention).
- the reason why the temperature range is set to the range of ⁇ 50 to + 300 ° C. is that the mold temperature is controlled within the above temperature range in the fusion press working method of the present invention.
- the water-soluble dry solid film lubricant for example, the lubricant disclosed in Patent Document 1 has a kinematic viscosity at 40 ° C.
- An organic compound thin body such as Teflon is also a lubricating substance that exhibits good lubricating performance in a wide temperature range, but it is difficult in terms of price and handling.
- the press working method (drawing) method for the end group part of the superconducting acceleration cavity has been described above.
- the molded product has a predetermined usable height.
- the shape freezing property and dimensional accuracy must be within a predetermined range. Therefore, according to a sixth aspect of the present invention, a re-striking process is performed on the molded body subjected to the fusion press process from the viewpoint of shape and dimensional accuracy. It has been generally practiced to perform restricking after pressing.
- a drawn product obtained by the press working method of the present invention is capable of performing restructuring and two-dimensional processing due to uniform strain and reduced dislocation density. It is characterized in that the deformation margin in the next machining is in a significantly increased state.
- FIG. 8 is a design drawing of HOM cup, which is one of the end group parts of the superconducting acceleration cavity, and the thickness of the entire molded body is 2.5 ⁇ 0.5 mm, and the inner diameter accuracy is 42 ⁇ .
- 0.1 mm roundness is defined as 0.2 mm
- cylindricity is defined as 0.1 mm.
- the fusion press working of the present invention in which deep drawing is formed by a single step press working has a difficulty in shape freezing as compared with the conventional multiple press working-heat treatment method and the like.
- all the press-processed products according to the present invention can be kept within tolerances by restructuring. This is mainly interpreted as a positive effect of mold temperature / distribution / gradient control. That is, from the viewpoint of material deformation, the molded product of the present invention in which the temperature distribution and temperature gradient of the workpiece are optimized by controlling the temperature / distribution / gradient of the mold is in a relatively uniform strain state, It is presumed that good shape and dimensional accuracy were obtained because the deformation margin for the subsequent processing remains.
- the seventh invention of the present invention is a processing method for performing any one or more of the secondary processing after the press processing or wrist-like processing described above, trimming processing, protrusion processing of the center portion of the bottom of the flat bottom, and burring processing. is there.
- the above-described press work or subsequent re-striking process is referred to as “primary work”
- the processed product is referred to as “primary work product”.
- the secondary processing the protrusion processing of the center portion of the flat bottom, the eccentric drilling and the burring processing are performed as the secondary processing on the primary processed product. It is necessary.
- the strain state of the primary processed product of the present invention is secondary as compared with the processed product manufactured by the conventional full-machine cutting method, extrusion-mechanical cutting-heat treatment method, multiple press processing-heat treatment method, etc. It was expected to be severe for processing.
- the above-mentioned secondary processing is applied to the primary processed product that has been subjected to re-striking after pressing by the method of the present invention, it is designated in the drawing of FIG. 8 without performing special processing such as heat treatment.
- the press working mainly composed of a single step drawing, a servo mechanism capable of controlling the speed and / or motion of the slide, and the temperature of the mold / It is necessary to use a press machine equipped with a temperature control device (two systems of heating and cooling) capable of controlling distribution and gradient.
- a temperature control device two systems of heating and cooling
- the appearance of the servo press is shown in FIG.
- the servo press machine preferably includes a servo die cushion device and a die capable of dynamically controlling the wrinkle presser load in addition to the servo mechanism and the temperature control device. If there is no servo press, a servo mechanism may be provided.
- the entire machine cutting method, extrusion-mechanical cutting-heat treatment method or multiple press working- can be manufactured from a pure niobium plate material by a single step press working mainly consisting of drawing.
- press-processed product of the present invention is also excellent in restricability and secondary processability is that the deformed structure and deformed state after press working are uniform.
- the present invention it is possible to manufacture an end group component of a superconducting acceleration cavity using a pure niobium plate material as a starting material and consistently pressing.
- the main processes can be summarized as follows: “Deep drawing by pressing” ⁇ “Restriking for accuracy of shape dimensions” (hereinafter “Primary processing”) ⁇ “Secondary processing”.
- Primary processing “Restriking for accuracy of shape dimensions”
- Secondary processing the manufacturing method of the HOM cup among the superconducting acceleration cavity end group parts has been described.
- the processing method of the present invention can be sufficiently applied to the beam pipe and the port pipe.
- FIG. 10 is a pure niobium material having a plate thickness of 2.8 mm, a circular blank of D 0 : 76 mm, and a flat bottom cylindrical punch of D p : 42 mm, using the servo press shown in FIG. 9 (hereinafter the same).
- FIG. 10 (a) shows the result of drawing, and as a result of forming at a processing speed V: 5 mm / min at room temperature, necking occurs in the vicinity of the punch shoulder, and it is in a state just before breakage.
- FIG. 10 (b) shows the same circular blank pure niobium material as above, with the temperature controlled to T d : 120 ° C. and T p : ⁇ 20 ° C., and after the punch contacts the workpiece, the processing speed is further increased.
- V Approximately 10 mm at 5 mm / sec (hereinafter referred to as “h”), and the stroke is stopped for 5 sec in order to optimize the temperature distribution and temperature gradient of the workpiece (hereinafter referred to as this stop).
- FIG. 11 (a) is a pure niobium material with a thickness of 2.8 mm, and circular blanks of various diameters using a flat bottom cylindrical punch with D p : 42 mm at a processing speed V of 5 mm / sec.
- 11B is a pure niobium material having a thickness of 2.8 mm, a circular blank of D 0 : 100 mm, and a flat bottom cylindrical punch of D p : 42 mm, T d : 120 ° C., T p : Under conditions controlled to -20 ° C, h: up to 10 mm, V: 5 mm / sec, t: Stop for 5 sec (V: 0), then V: 100 mm / sec, wrinkle presser stress until then The increase in the deformation stress ⁇ d of the flange due to the increase in speed is suppressed by the decrease in the dynamic friction coefficient due to the increase in speed and the reduction of the wrinkle pressing force (stress).
- FIGS. 11 (a) to 11 (c) which is a room temperature processed product, with respect to the molding height (usable height) of the concave ear portion that can be effectively used in the three processing examples shown in FIGS. 11 (a) to 11 (c).
- the room temperature processed product and the fusion press processed product of the present invention regardless of whether the blank shape is circular or irregular, and the latter is remarkably superior.
- the size of the ears and the height of the concave ears change greatly depending on the shape and dimensions of the blank, and the deformed blank is superior.
- FIG. 12 shows a semi-quantitative summary of the effects of the factors in the press working on the formability. From this figure, in pure niobium material, a certain degree of effect is recognized as shown in FIG. 7 even by temperature control of T d and T p known as a warm working method. It is impossible to manufacture parts by press working, and it is necessary to optimize the temperature distribution and temperature gradient of the workpiece by controlling the speed / motion of the slide using a servo mechanism. It is also important to mitigate the increase in the processing speed itself and the increase in flange deformation resistance associated therewith by reducing the dynamic wrinkle presser load.
- the processing object of the present invention is a flat bottom cylinder, and a circular shape is usually used for the blank. Is effective. In the present invention, this is simply referred to as “deformation (deformed blank)”.
- the difference between the height difference ( ⁇ E) between the convex ear and the concave ear and J is as follows.
- a convex negative correlation was observed, and the ear was closest to isotropic, that is, ⁇ E ⁇ 0, when J: 1 / 11.5. Therefore, the blank used in the examples of the present invention in the following examples was, as a rule, a deformed blank obtained using this J value.
- the r value governing the in-plane anisotropy is determined by the crystal texture of the material and varies depending on the angle ⁇ with respect to the rolling direction. Therefore, in the case of macroscopic drawing, the respective deformation states in the circumferential direction, the plate thickness direction, and the radial direction of the flange change depending on the position in the blank, and the extent depends on the blank shape dimension. .
- FIG. 14 shows, as in FIG. 13 (a), a delayed fracture (placement) after several days after processing on the concave ear portion of a flat bottom cylindrical molded body that has generated large four ears by deep drawing a perfect circle blank.
- This shows a processed product in which cracks and vertical cracks) occurred.
- the concave portion corresponds to the direction of ⁇ : 45 ° from the rolling direction, the tensile strain in the radial direction is small, the tensile residual stress is larger than that of the convex portion, and the shape notch effect acts to cause cracks. I think it has come. Therefore, in the formation of pure niobium material, it is important to suppress the occurrence of ears due to anisotropy in order to prevent delayed fracture. It is preferable to adopt.
- the effects obtained by using the deformed blank are as follows. (1) Usable height of a cylindrical drawn product is improved by reducing (isotropic) ears. (2) The drawability is improved compared to a circular blank having the same area (see FIG. 7). (3) Since the amount of material necessary to obtain a predetermined usable height can be reduced, the material cost of an expensive pure niobium material can be reduced (approximately 10%). (4) Delayed fracture at the edge of the cylindrical drawn product can be prevented.
- FIG. 8 shows a design drawing of the HOM cup as an example.
- the shape and dimensional accuracy of the end group parts of the superconducting accelerating cavity strict requirements are made in consideration of the performance of the accelerator. For this reason, the molded body obtained by the fusion press working method of the present invention needs to be subjected to restricking in order to further improve the shape freezing property and dimensional accuracy.
- FIG. 15 shows a flat-bottom cylindrical shaped body obtained by drawing a deformed blank made of pure niobium with a thickness of 2.8 mm and J: 1 / 11.5 by the fusion pressing method of the present invention.
- the inner diameter of each orientation at the height position of the illustrated cylinder was measured, and the roundness (specification: within 0.2 mm) and cylindricity (specification: within 0.1 mm) were examined. The results are shown.
- the roundness is 1 ⁇ 2 of the diameter difference in each radial direction at the same height position
- the cylindricity is 1 ⁇ 2 of the diameter difference in each height position in the same radial direction.
- the specifications of the plate thickness accuracy at each part are 2.5 ⁇ 0.5 mm, and the inner diameter accuracy is 42 ⁇ 0.1 mm, and it has been confirmed that both are sufficiently satisfied.
- the secondary processing includes projection processing of a cylindrical flat bottom surface, eccentric drilling, and burring processing.
- FIG. 16 shows the result of projecting a protrusion of about 10 ⁇ ⁇ 6 mm height on the bottom surface of the HOM cup (primary processed product) after the restric process.
- this protrusion is mechanically cut, or in the case of extrusion-mechanical cutting-heat treatment method or multiple press working-heat treatment method, a separately prepared protrusion is welded by electron beam welding EBW.
- EBW electron beam welding
- FIG. 17 (a) shows the result of eccentric drilling and burring on the HOM cup that has been subjected to the above protrusion processing.
- the burring process as shown in the figure, after drilling at a position eccentric from the central axis of the cylinder, eccentric burring was performed by the thrust of the piston by a high-pressure pump. However, the final finishing step was performed by machine cutting. Stretch flangeability (deformation mode that is the main burring process) has anisotropy even after drawing, so this processing is not easy considering that the hole position is eccentric. .
- FIG. 17B shows the result of inspecting the occurrence of microcracks due to burring by color check after the mechanical cutting, and it was confirmed that there were no cracks.
- the technology of the present invention is excellent in deep-drawn formability of difficult-to-process materials, for example, it is also used as a method for manufacturing a seamless pipe having a required length by trimming the rim and bottom after deep drawing. be able to.
Abstract
Description
(1)空洞部品は、超伝導線材とは異なり一種のマッシブな構造体であるため、単体純金属であることが望ましい。
(2)幾つかの候補金属の中で、ニオブの超伝導転移温度が9.2K(常圧下)で最も高い(超伝導状態では、電気抵抗がゼロになり、発熱や熱伝導は問題でなくなる)。
(3)高純度ニオブは、遷移金属に属し、溶融点から極低温までの広範な温度領域において体心立方格子を有し、相変態を生じない安定な材料である。
(4)高純度ニオブは、常温近傍では極めて軟質な材料で、強度が不足するため、加工難度が高く、また、体心立方結晶格子であるため、低温では加工硬化が激しく、脆性破壊を生じ易い特性を有するものの、加工が不可能とはいえない。
(5)高純度ニオブは、空気中では酸化被膜が形成され、耐食性および耐酸性を有するため、常温でのハンドリングがし易い。
なお、超伝導加速空洞のセンター部分については、特許文献1に、スライスしたNb板素材をプレス加工でハーフカップとし、これを電子ビーム溶接EBWで接合して製造する方法が開示されている。しかし、上記プレス加工は、室温での浅絞り法であり、エンドグループ部品の製造に適用できる技術ではない。
(1)ロッド素材から機械切削加工のみで製造する方法(以降、「全機械切削法」ともいう。)
(2)ロッド素材の後方押出し加工と、機械切削と、熱処理とを組み合わせて製造する方法(以降、「押出し-機械切削-熱処理法」ともいう。)
(3)板素材から、複数工程のプレス加工と、上記プレス工程間において複数回の熱処理を施して製造する方法(以降、「複数プレス加工-熱処理法」ともいう。)
Dθ=D0(r45/rθ)J ・・・(9)
ここで、Dθ:圧延方向から角度θ方向のブランク径
D0:圧延方向から45°方向のブランク径
rθ:圧延方向から角度θ方向の塑性歪比r
J:定数(1/10~1/13)
から決められる非真円異形ブランクとすることを特徴とする(第4発明)。
以下、この第2発明について説明する。
[LDR]≡(D0/Dp)ma× ・・・(1)
(ただし、D0:円ブランク径,Dp:ポンチ径)
なお、平頭ポンチの場合は、下記(2)式で表わされる。
[LDR]={√(1+R)/2}・{(1+R)/√(1+2R)}n ・・・(2)
ここに、Rは下記(3)式;
R=(r0+r90+2r45)/4) ・・・(3)
(ただし、0,45,90は圧延方向を0とした角度θ)
で求められる塑性歪比r値の平均値であり、上記r値は、下記式で定義される。
r≡εw/εt
(ε:真歪ε=ln(1+λ)、λ:慣用歪、w,t:単軸引張試験片の幅と厚み)
また、nは、加工硬化指数であり、下記σ-εべき乗関係式の指数である。
σ=Cεn ・・・(4)
(ただし、σ:真応力(=s(1+λ)、s:慣用応力、C:定数)
lnσ=A+(Q/kT) ・・・(5)
σ=K(dε/dt)m ・・・(6)
ここに、A,Kおよびmは定数、Qは活性化エネルギー、kはボルツマン定数である。 発明者らは、純ニオブの加工変形挙動を調べたところ(4),(5),(6)式が、現に成り立つことを確認している。
σcr=(2/√3)1+n・[{(1+R)/2}/{√1+2R/3}]1+n・σu(t0/t) ・・・(7)
(σuは引張最大真応力,t0およびtはそれぞれ加工前後の板厚)
周知のごとく、しわ押え荷重は、プレス加工におけるしわを防止するため、材料が破壊を生じない範囲に設定し、加工終了(絞り抜け)まで、当初負荷した一定荷重に保持するのが普通である。そうした中で、絞りの進行に伴うフランジ面積の変化や、素材板厚の変化、成形荷重の変化を考慮しながら、加工行程中にしわ押え力を動的に変化する「可変しわ押え方式」が提案されている。この方法は、素材のr値とその異方性による微視的な方位変動と、力学的な縮みフランジ変形による巨視的な板厚の増大という、いずれも、絞り性を阻害する要因を緩和する効果があるので、絞り性の向上が期待される。
発明者らの調査・研究によれば、異方性の改善が、成形性の向上にも寄与することが明らかとなっている。絞り成形における異方性は、主として素材の面内異方性に起因する。素材の面内異方性を表わす定量値としては、既述のr値の平均値Rおよび下記(8)式で表される面内異方性の大きさ|Δr|がある。
|Δr|≡|{(r0+r90)/2}-r45| ・・・(8)
通常、円筒絞りのブランク(素板)には、真円形状のものが用いられる。素材が等方性であれば、耳の問題は生じないからである。しかし、現実の純ニオブ材の塑性歪比r値には、普通鋼板と比較して、強い圧延方向からの方向(θ)依存性があり、面内異方性が大きい。面内異方性を有する素材を絞り成形した場合には、r値の大きい方向では板厚の変化が小さく、小さい方向では大きい。そのため、円筒絞りの場合には、円周方向と板厚方向に縮みフランジ変形が、半径方向では伸びフランジ変形が生じるため、r値が大きい方向では板厚増加が起こり、材料が半径方向に逃げて凸耳となり、逆に、r値が小さい方向では板厚増加が小さいので、材料が半径方向に逃げる量が少なく凹耳となる。
Dθ=D0(r45/rθ)J ・・・(9)
ここで、Dθ:圧延方向から角度θ方向のブランク径
D0:圧延方向から45°方向のブランク径
rθ:圧延方向から角度θ方向の塑性歪比r
J:定数
から決められる形状・寸法の異形ブランクとする。
また、上記定数Jは、被加工材が有する異方性によって定まる定数であり、被加工材の種類や製造履歴等によって変動するが、純ニオブ板素材の場合、一般に、1/10~1/13の範囲内にある。なお、後述するように、本発明の実施例に用いた純ニオブ板素材では、凸耳高さと凹耳高さの差ΔE≒0になる定数Jは(1/11.5)である。
・ステップ1:素材ごとまたは素材ロットごとに、rθ(圧延方向を0°として、それから角度θをなす方向のr値)を、例えば15°おきに実測する(r値の測定方法は、JIS Z2254に記載の方法を用いることができる。)。
・ステップ2:上記r値の信頼性を検証(再現性の確認や、θ間隔の適正化等)した上で、最小二乗法の適用によるデータの確認後、3次Bスプライン補間法によってθ-rθ関係を規定する。
・ステップ3:ニオブは、体心立方金属であることから、r45が最小値となるので、円ブランク径D0=D45となるよう基準決めを行い、θ方向のブランク径Dθを求めるため、前述した(9)式(べき乗仮説式)を導入し、上記J値とrθの実測値から、異形ブランクの形状・寸法を算出する(上述のように、θ=45°のときのDθ=D0を基準とする)。
そこで、本発明における第6発明は、上記融合プレス加工を施した成形体に、形状・寸法精度の観点から、リストライク加工を施す。なお、プレス加工後、リストライク加工を施すことは、従来から一般に行われているが、本発明のプレス加工法による絞り成形体は、歪の均一化と転位密度の低下によって、リストライクや二次加工における変形の余裕度が著しく増加した状態にあることが特徴である。
具体的には、図8は、超伝導加速空洞のエンドグループ部品の一つであるHOM cupの設計図であり、成形体全体の板厚は2.5±0.5mm、内径精度は42±0.1mm、真円度は0.2mm、円筒度は0.1mmと規定されている。この基準は、単一工程のプレス加工で深絞り成形する本発明の融合プレス加工には、従来の複数プレス加工-熱処理法等と比較して、形状凍結性に難があることが懸念された。しかし、本発明にプレス加工品は、リストライク加工によって、すべて公差内に収めることができた。これは、主として、金型の温度/分布・勾配制御がプラスに作用したものと解釈している。つまり、材料変形の観点から考えると、金型の温度/分布・勾配制御によって、被加工材の温度分布および温度勾配を適正化した本発明の成形品は、比較的均一な歪状態にあり、その後の加工に対する変形余裕度が残されているため、良好な形状・寸法精度が得られたものと推察している。
本発明が加工対象とする図8に示したHOM cupの場合、リストライク後の一次加工品に、二次加工として、平底底面中央部の突起出し加工、および、偏芯穴あけとバーリング加工を施すことが必要である。
上記に説明した本発明の融合プレス加工を実施するためには、主として単一工程の絞り成形からなるプレス加工を、スライドの速度および/またはモーションの制御が可能なサーボ機構と、金型の温度/分布・勾配制御が可能な温度制御装置(加熱および冷却の2系統)を備えたプレス機を用いて行うことが必要である。一例として、上記サーボプレス機の外観を図9に示す。
さらに、上記サーボプレス機は、上記のサーボ機構や温度制御装置に加えて、しわ押え荷重の動的制御が可能なサーボダイクッション装置や金型を備えたものであることが好ましい。なお、サーボプレス機がない場合には、サーボ機構を付設すればよい。
なお、上記説明では、超伝導加速空洞エンドグループ部品のうちのHOM cupの製造方法について述べてきたが、本発明の加工方法は、Beam pipeやPort pipeへの適用も十分に可能である。
図10は、図9に示したサーボプレス機を用いて(以降、同様)、板厚2.8mmの純ニオブ材で、D0:76mmの円形ブランクを、Dp:42mmの平底円筒ポンチで絞り成形した結果を示したものであり、図10(a)は、室温で加工速度V:5mm/minにて成形した結果、ポンチ肩部近傍部にネッキングが生じて破断寸前の状態にあり、この後、数mm足らずのストロークの進行により破断した加工例である。また、図10(b)は、上記と同じ円形ブランクの純ニオブ材を、Td:120℃,Tp:-20℃に温度制御し、ポンチが被加工材に接触後、さらに、加工速度V:5mm/secで約10mm(以降、この加工量を「h」とする)加工し、被加工材の温度分布と温度勾配を適正化するために5sec間ストロークを停止し(以降、この停止時間を「t」と表す)、その後、V:5mm/minで成形を進め、上記室温での絞り成形と同じ絞り高さのところで加工を停止した加工例である。この例では、ポンチ肩部近傍には、ネッキングは全く生じておらず、その後のストロークの進行により絞り抜けた(凹耳の絞り高さは27mm)。この結果から、室温かつ一定速度で加工する従来の加工法と、金型の温度/分布・勾配制御とスライドの速度/モーション制御を行う本発明の融合プレス加工法とでは、加工性に明確な差が認められる。
図13に示した3個の平底円筒状の絞り成形品は、絞り高さが同じであるにも拘らず、口縁部の凹凸状況、即ち、耳の大きさが異なっている。これらはいずれも、ブランク形状・寸法を除いて、実施例1の図11(c)と同じ、本発明の融合プレス加工法で絞り成形したものである。ただし、前述した(9)式におけるパラメーターJについては、図13(a)のブランクはJ:0(真円)、図13(b)はJ:1/6、図13(c)はJ:1/11.5とした(ただし、D45=D0はすべて同じ)。
上記の図13の結果と、J値をもう少し細かく変化して別途行った実験結果と合わせてみると、凸耳と凹耳の高さの差(ΔE)とJとの間には、下に凸の負の相関が認められ、耳が等方性に最も近くなる、即ち、ΔE≒0となるのは、J:1/11.5のときであった。そこで、以降の実施例の本発明例に用いるブランクは、原則として、このJ値を用いて求めた異形ブランクとした。
面内異方性を支配するr値は、材料の結晶集合組織によって決まり、圧延方向に対する角度θに依存して変化する。そのため、巨視的な絞り成形の場合、フランジの円周方向、板厚方向、半径方向におけるそれぞれの変形状態は、ブランク内の位置によって変化し、その程度がブランク形状寸法に依存するということである。
上記凹部分は、圧延方向からθ:45°方向に相当し、半径方向の引張歪が小さく、凸部に比べて引張残留応力が大きいことと、形状的なノッチ効果が作用して亀裂発生に至ったものと考えている。したがって、純ニオブ材の成形にあたっては、遅れ破壊を防止するためにも異方性に起因した耳の発生を抑制することが重要であり、そのためには、r値の分布を考慮した異形ブランクを採用することが好ましい。
(1)耳の低減(等方化)による円筒絞り成形品の使用可能高さが向上する。
(2)同じ面積の円ブランクに比べて絞り性が向上する(図7参照)。
(3)所定の使用可能高さを得るのに必要な素材量を削減できるので、高価な純ニオブ素材の材料費を削減できる(大略10%程度)。
(4)円筒絞り成形品の口縁部における遅れ破壊を防止できる。
図15は、板厚2.8mmの純ニオブ材で、J:1/11.5とした異形のブランクを、本発明の融合プレス加工法で絞り成形して得た平底円筒形状の成形体に、リストライク加工を施した後、図示した円筒の高さ位置における各方位の内径を測定し、真円度(仕様:0.2mm以内)および円筒度(仕様:0.1mm以内)を調べた結果を示したものである。なお、上記真円度とは、同一高さ位置の各半径方向における直径差の1/2、また、上記円筒度とは、同一半径方向の各高さ位置における直径差の1/2、と定義している。因みに、各部位における板厚精度の仕様は2.5±0.5mm、内径精度は42±0.1mmであり、いずれも十分に満足していることを確認している。
図8に示したHOM cupの設計図面に記された部品とするためには、上記絞り成形とリストライク加工後の一次加工品に、いわゆる補足的な二次加工を施すことが必要である。それによって、HOM cupが、超伝導加速空洞の超伝導特性を機能的に発揮するからである。具体的には、図1および図2に示したように、電子ビーム溶接EBWによってHOM antennaと一体化して、HOM couplerに組み立て、ポートパイプやビームパイプ等のエンド部品とともに空洞機能を発揮する。上記二次加工には、円筒平底面の突起出し加工、偏芯穴あけやバーリング加工がある。
しかし、本発明の一次加工品は、HOM cupの底面に、肉寄せのための予備成形を挟んで突起出しプレス加工することで、容易に突起出しを行うことができた。
伸びフランジ性(バーリング加工の主体となる変形様式)には、絞り成形後においても異方性が存在するので、穴位置が偏芯していることを考慮すると、この加工は容易とはいえない。しかし、穴形状や穴周辺の側壁の肉厚を適正化し、バーリング加工温度を100℃程度に高めることで、図8に示した所定の要求を満たす寸法に加工することができた。これも、本発明の融合プレス加工品の伸びフランジ性が、加工後の熱処理なしでも、従来の加工品に比べて、変形余裕度を有しているからである。なお、図17(b)は、上記機械切削加工後に、カラーチェックで、バーリングによる微小亀裂の発生有無を検査した結果を示したもので、亀裂発生がないことが確認された。
以上の結果から、本発明の融合プレス法を用いることにより、熱処理等、特別な処理を必要とすることなく、HOM cupのほぼ全ての製造工程を、プレス加工で行うことが可能であることがわかる。
Claims (8)
- 荷電粒子の加速に用いられる超伝導加速空洞のエンドグループ部品の製造方法であって、純ニオブ板素材から、主として平面円筒絞りからなるプレス加工で製造することを特徴とするエンドグループ部品の製造方法。
- 上記プレス加工において、スライドの速度および/またはモーションの制御と、金型の温度および/または分布・勾配の制御を同時に行うことを特徴とする請求項1に記載のエンドグループ部品の製造方法。
- 上記プレス加工において、上記純ニオブ板素材のフランジ面積、板厚および材質の変化に応じて、しわ押え荷重を動的に制御することを特徴とする請求項1または2に記載のエンドグループ部品の製造方法。
- 上記純ニオブ板素材のブランクを、塑性歪比の実測値と、下記(9)のべき乗仮説式から決められる非真円異形ブランクとすることを特徴とする請求項1~3のいずれか1項に記載のエンドグループ部品の製造方法。
記
Dθ=D0(r45/rθ)J ・・・(9)
ここで、Dθ:圧延方向から角度θ方向のブランク径
D0:圧延方向から45°方向のブランク径
rθ:圧延方向から角度θ方向の塑性歪比r
J:定数(1/10~1/13) - 上記プレス加工の潤滑剤として、-50~+300℃間における動粘度の温度変化が±10%以内の水溶性固形被膜型潤滑剤を用いることを特徴とする請求項1~4のいずれか1項に記載のエンドグループ部品の製造方法。
- 上記プレス加工後、リストライク加工を施すことを特徴とする請求項1~5のいずれか1項に記載のエンドグループ部品の製造方法。
- 上記プレス加工またはリストライク加工後、トリミング加工、底面突起出し加工およびバーリング加工のいずれか1以上の加工を施すことを特徴とする請求項1~6のいずれか1項に記載のエンドグループ部品の製造方法。
- 上記プレス加工を、スライドの速度および/またはモーションの制御が可能なサーボ機構と、しわ押え荷重を動的に制御する動的しわ押え制御装置とを備えるプレス機と、
被加工材の温度および/または分布・勾配制御が可能な温度制御装置および金型とを用いて行うことを特徴とする請求項1~7のいずれか1項に記載のエンドグループ部品の製造方法。
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CA2863020A CA2863020C (en) | 2012-02-02 | 2013-02-04 | Method of manufacturing end-group components with pure niobium material for superconducting accelerator cavity |
EP13743012.0A EP2810722B1 (en) | 2012-02-02 | 2013-02-04 | Method of manufacturing pure niobium end group components for superconducting acceleration cavity |
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US9502631B2 (en) | 2012-02-02 | 2016-11-22 | Shinohara Press Service Co., Ltd. | Method of manufacturing end-group components with pure niobium material for superconducting accelerator cavity |
JP2017109223A (ja) * | 2015-12-16 | 2017-06-22 | しのはらプレスサービス株式会社 | 新せん断打抜き加工法を用いた金属製品の製造方法 |
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JP7361877B1 (ja) | 2022-12-23 | 2023-10-16 | しのはらプレスサービス株式会社 | 金属材料の準静的室温擬超塑性プレス加工方法 |
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EP2810722A1 (en) | 2014-12-10 |
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